An integrated approach for validating micro mechanical systems based on simulation and test

Abstract

Miniaturization of macroscopic mechanical systems enables the opening of new areas of application for micro technological systems. Because of technological restrictions, especially when applying miniaturized conventional manufacturing techniques, shape and material deviations cannot be scaled down in the same dimension like micro parts. Thus, the long-term objective is to ensure the functioning by appropriate design measures. In doing so, determination of the transfer behavior by modeling and simulation is required. This work presents two ways for ensuring the required properties of micro gears and describes how the results do correlate. The experimental way uses the radial composite inspection as it is used in the macroscopic world. The simulative way deploys a rolling simulation by utilization of finite element analysis. The virtual prototypes are originated on measured real test gears. When comparing experiment and simulation of the rolling behavior, in some short and long wave areas deviations can be recognized. These can be ascribed to the reduction from three to two dimensions when modeling. Other deviations might be based on inaccuracies when mounting into the test rig. In other areas quite good correlations of test and simulation could be ascertained.

Micro gear validation: improving the correlation between virtual and physical testing

“…1. Previous work compared the results of simulated and real radial composite inspections for validation of the proposed threefold approach (Albers et al 2008a). The results corresponded well to some extent but the quality of the correlation varied along the results curve.…”

“…Prior investigations (Albers et al 2008a) already exposed the difficulties found when using the fastest and less complex modeling and simulating approaches with ceramic micro gears. No satisfactory, overall correlation between measurement and simulation could be found, neither for the long nor for the short wave domains of a radial composite inspection deviation chart.…”

“…For modeling the gears, the method introduced in Albers et al (2008a) has been adopted again. All components were reduced to plain components.…”

“…The overall gear diameter is 1.2 mm; the bush bearing hole in the centre has a diameter of 500 lm. Recent research (Albers et al 2008a) proposed a threefold methodological approach integrating dimensional measurement, virtual tests of measured real gears and physical tests of real gears. All these activities are embedded into a research project on primary-shaping of microparts made of metallic and ceramic materials (CRC499 2009).…”

Methods for simulating and optimizing molded micro components and systems

“…The interaction between the teeth (gearing) is modeled again as a 'hard' contact and frictionless behavior. The flank geometry modeled, thus being parametric, is still away from the real profiles measured on probes (Albers et al 2008c). Selection of the best simulation methodology to perform the system simulations is based on previous research work by the group (Albers et al 2008a).…”